Apparatus for securing buttons to fabric

ABSTRACT

A method and apparatus for securing buttons to fabric. The method comprises providing a button with a thermoplastic portion and securing the button to fabric by applying ultrasonic energy to the thermoplastic portion which enables securement between the button and the fabric by the flowing of the thermoplastic portion into the fabric.

United States Patent Jacobs et al.

[451 Mar.21, 1972 APPARATUS FOR SECURING BUTTONS [56] TO FABRIC Inventors: Herbert V. Jacobs, Lower Merion, Pa;

Donald Kirk, Jr., St. Petersburg, Fla.

Assignee: Jacobs Machine Corporation, West Conshohoken, Pa. by said Herbert V. Jacobs Filed: May 21, 1969 Appl. No.: 826,587

US. Cl. ..425/109, 24/90 HA, 264/23, 264/249, 425/174 Int. Cl. ..B29c 3/00 FieldofSearch ..18/16R,16C,l6E,l6F, 18/16 H, 16 P, 16 T, 36; 25/41 .1; 264/23, 68, 249;

24/90 l-lA References Cited UNlTED STATES PATENTS 2,470,963 5/1949 Weyl ..24/90 HA 3,427,688 2/1969 Wilson 18/36 T 3,462,803 8/1969 Horton ..24/90 HA FOREIGN PATENTS OR APPLICATIONS 995,680 7/1949 France ..24/90 HA Primary ExaminerRobert D. Baldwin Assistant Examiner-Lucius R. Frye Attorney-Caesar, Rivise, Bernstein & Cohen [5 7] ABSTRACT A method and apparatus for securing buttons to fabric. The method comprises providing a button with a thermoplastic portion and securing the button to fabric by applying ultrasonic energy to the thermoplastic portion which enables securement between the button and the fabric by the flowing of the thermoplastic portion into the fabric.

4 Claims, 9 Drawing Figures Patented Marth 21, 1972 3,650,647

2 Sheets-Sheet l mvnvrons. V. J AC 0 BS HERBERT DONALD KIRK,JR.

Arron/Era,

Patented March 21, 1972 3,650,647

2 Sheets-Sheet 2 HERBERT v. JACOBS DONALD KIRK,JR. BY

4 TTORA/EYS'.

APPARATUS FOR SECURING BUTTONS T FABRIC This inventionrelates generally to the securement of buttons to fabric and more particularly to the securement of the buttons to fabric by the application of ultrasonic energy.

Buttons have historically been fastened to fabric by sewing. However, the trend towards manufacture of clothing by automated processes has produced a need for a method of securement of buttons to fabric by a faster method than sewing. That is, the speed of production of items of apparel having buttons secured thereto is greatly reduced because of the time required to sew the buttons to the fabric.

-Various methods of speeding up the sewing of the buttons to the fabric have been used. For example, a plurality of sewing machine heads are aligned in one system so that a plurality of buttons can be secured to the fabric simultaneously.

For example, in the production of shirt fronts, a plurality of sewing machines can be used simultaneously to sew two or three buttons on the shirt front simultaneously. That is, conventionally made shirts normally have five or six buttons on the shirt front. Because the buttons on a shirt front are placed close together, the spatial requirements of sewing machine heads preclude having a pair of sewing machines provide adjacent buttons simultaneously. The closest that the sewing machines can be placed is for alternate buttons. Therefore, in a first operation of sewing, the first, third and fifth buttons are sewed on and in the second sewing machine operation, the second, fourth, and where provided, the sixth button are sewed on simultaneously.

It can therefore be seen the speed of manufacture of shirts is reduced by the time consumed in sewing the buttons to the fabric and is further limited by the spatial requirements which prevent adjacent buttons from being sewn simultaneously. Thus, two sewing operations must be provided in order to sew the full complement of buttons to a shirt front.

Various means have been provided to secure buttons to fabric by other than sewing machines. For example, it has been suggested to secure a button to fabric by providing a button with a thermoplastic material then providing heat to the thermoplastic material in order to cause the melted plastic to run from the button through the fabric and then be reset by cooling about the material. However, in order to attach buttons by this method, the time required for heating the thermoplastic material is longer than the time taken to sew the buttons to the material. That is, were heat applied too quickly to the thermoplastic material, the cloth or fabric to which the button is attached would be burned. Consequently, this method of securing a button to the fabric is not only too time consuming but also very inconsistent in that the amount of material which is melted in each application varies.

It is therefore an object of the invention'to overcome the aforementioned disadvantages of securing buttons to fabric.

Another object of the invention is to provide a new and improved apparatus for securement of buttons to fabric which provides a uniform securement in a short period of time.

Yet another object of the invention is to provide a new and improved apparatus for securement of buttons to fabric which utilizes ultrasonic energy for the fastening therebetween.

Yet another object of the invention is to provide a new and improved button which is capable of being secured to fabric by ultrasonic energy.

Still another object of the invention is to provide a new and improved method of making a button suitable for securement to fabric by means of ultrasonic energy.

Another object of the invention is to provide a new and improved apparatus for securement of a heavy duty button to material having no ultrasonic response characteristics.

These and other objects of the invention are achieved by providing a method of securing buttons to fabric which comprises the steps of: providing a button with a thermoplastic portion; placing the thermoplastic portion of the button against the fabric; aligning an ultrasonic ram with said thermoplastic portion and abutting the button with the ram; applying ultrasonic energy to the ram which is transmittedto the thermoplastic portion of the button and the material and which causes the thermoplastic portion to flow into the fibers of the fabric to secure the button to the fabric.

Other objects and many of the attendant advantages of this invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a diagrammatic side elevational view of an apparatus for securing button to fabric embodying the invention with portions shown in vertical section for purposes of clarity to illustrate the invention;

FIG. 2is a perspective view of the bottom portion of a button embodying the invention;

FIG. 3 is an enlarged sectional view taken along the line 3 3 in FIG. 2;

FIG. 4 is a diagrammatic side elevational view with portions shown in vertical section for purposes of clarity of the button secured to fabric after ultrasonic energy has been applied to the button;

FIG. 5 is a diagrammatic side elevational view of an apparatus for making a button which is not ultrasonically responsive suitable for ultrasonic securement to fabric with portions shown in vertical section for purposes of clarity;

FIG. 6 is a bottom plan view of the button shown in FIG. 5 taken along the line 66 in FIG. 5;

FIG. 7 is a diagrammatic side elevational view with portions shown in vertical section for purposes of clarity of the apparatus embodying the invention during the second step in making the button shown in FIG. 5 suitable for securement to fabric by ultrasonic means;

FIG. 8 is a diagrammatic side elevational view with portions shown in vertical section for purposes of clarity of the apparatus embodying the invention during the first step in securing the button shown in FIG. 7 to fabric; and

FIG. 9 is a diagrammatic side elevational view with portions shown in vertical section for purposes of clarity of the apparatus embodying the invention during securement of the button of FIG. 7 to fabric.

Referring now in greater detail to the various figures of the drawing wherein similar reference characters refer to similar parts, wherein apparatus for securing a button to fabric is diagrammatically illustrated in FIG. 1. The apparatus for securing a button to fabric includes a fixed ram 20, a button 22, fabric 24, a baseplate 26 and an ultrasonic ram 28.

The fixed ram 20 includes a cylindrical recess 29 for receiving the button 22. The recess 29 maintains the button in vertical alignment above the baseplate 26 as fabric 24 is slid therebetween. The fabric is drawn along and is supported by the baseplate 26.

As best seen in FIG. 2, the button preferably comprises a top disc portion 30 and a cylindrical boss or projection 32 which depends from the bottom surface of the disc portion 30 centrally thereof. The cylindrical projection 32 preferably includes an annular skirt 34 which forms the end of the projection 32. The skirt 34 depends from the end of the projection 32 and is of triangular cross-section. Also projecting from the lowermost surface of projection 32 are a plurality of conically shaped nipples 36. As will hereinafter be seen, the sharp points of the skirt and the nipples 36 aid in causing the thermoplastic material to flow very quickly as ultrasonic energy is applied thereto.

The button 22 is preferably comprised of a thermoplastic material which is responsive to ultrasonic energy. That is, when ultrasonic energy is applied by an ultrasonic ram to the ultrasonic material, the material heats up and is caused to flow.

The baseplate 26 includes an opening 38 which is aligned with the end of the ultrasonic ram 28 to enable the ram to be passed therethrough. The opening 38 is provided directly below the projection 32 of the button 22. The fabric 24 is preferably a double layer in thickness at the location of the securement of the button and is preferably ultrasonically responsive. That is, the fabric preferably includes a synthetic material or fiber which flows on the application of ultrasonic energy. It should be understood that the term ultrasonically responsive as applied to fabric would also include fabric which is predominantly comprised of material which is not ultrasonically responsive but which has some filaments of an ultrasonically responsive nature, such as thermoplastic or synthetic fibers, which are provided in the fabric in portions of the fabric at the location of the securement of the buttons.

The ultrasonic ram 28 comprises a coupling element for an ultrasonic generator. The shape of the ram 28 is generally conical with a cylindrical end portion 40. The generally conical shape of the ram 28 enables the intensity of the vibration to be most amplified at the end 40 of the ram.

The ram end 40 is preferably cylindrical so that it passes easily through the opening 38 in plate 26 without engaging the edge of the plate.

In order to secure a button 22 to fabric 24, the button 22 is placed in the recess 29 of the fixed ram 20. The fabric 24 is moved underneath the projection 32 until the specific location at which a button is to be secured is aligned with the projection. The ultrasonic ram 28 is moved vertically upward until it abuts the lower surface of the material 24 aligned with the projection 32.

Ultrasonic energy is then applied to the ram 28 which couples the ultrasonic energy to the thermoplastic projection 32 of the button 22 and the fabric 24 which thereby causes the thermoplastic material in projection 32 to be heated very quickly. That is, as indicated by arrows 42, the ram 28 moves up and down at an ultrasonic frequency thereby causing vibrations in the projection 32.

The pointed edges of skirt 34 and nipples 36 are brought to a liquid state very quickly because of the intensity of the vibrations of these points which cause a flowing of the material in the projection 32 into the fabric 24. Similarly, any thermoplastic material provided in fabric 24 also is caused to flow which is between the projection 32 and the ram 28 thereby causing a thermoplastic securement between the thermoplastic fibers and the thermoplastic material of the projection 32. When the ram 28 is lowered, the thermoplastic interconnection is thereby formed between the button 22 and the fabric 24 as best seen in FIG. 4.

It can therefore be seen that a new and improved method of securement of buttons to fabric has been provided. The button is secured to the fabric by thermoplastic flow which is induced by the ultrasonic energy applied thereto. The fabric 24 is caused to be secured to the button by the flow of thermoplastic material through the fibers. Where the fibers in the material or fabric are of a thermoplastic nature and thus ultrasonically responsive, the securement between the button and the fiber is enhanced by the intermolecular connection therebetween.

In many applications it is desired that the button secured to the fabric of the article of clothing be ofa heavy duty nature and therefore made of materials such as metal or very hard plastic. Where such a button is desired, it is contemplated that a thermoplastic portion be secured to a portion of the button which is not ultrasonically responsive.

Referring to FIG. 5, a device for making a button suitable for securement by ultrasonic means is provided. The apparatus basically comprises fixed ram 50 which is similar to ram 20, a button 52, a dieplate 54 and an ultrasonic ram 56. A layer of thermoplastic material 58 is fed between the plate 54 and the ultrasonic ram 56.

As best seen in FIG. 6, the button 52 basically comprises a disclike top member 60 and a lowermost projection 62 which are comprised ofa hard durable material. The lowermost projection 62 preferably includes an embossed or knurled bottommost surface 64. Embossed surface 64, as will hereinafter be seen, facilitates the securement ofa thermoplastic member to the projection 62.

The dieplate 54 includes a circular opening 66. The ultrasonic ram 56 is generally conically shaped and includes a cylindrical end member 68 which is substantially the same diameter as the opening 66. The thermoplastic material is preferably drawn past opening 56 and is disposed adjacent the lower surface of the dieplate 54.

Button 52 is secured within the recess of the fixed ram 50. The recess 70 includes means such as a suitable adhesive or fingers (not shown) which fix the button 52 to the top surface of the recess. In order to secure the layer of thermoplastic to the projection 62, the ultrasonic ram 56 is elevated vertically as best seen in FIG. 7 causing a cylindrical portion 72 of the thermoplastic material to be punched through the opening 66 in the dieplate 54.

The ram 56 is elevated until end 68 abuts the surface 64 of the button with the thermoplastic portion 72. Ultrasonic energy is then applied to the ram 56 thereby causing the ram to vibrate up and down at an ultrasonic frequency which causes the cylinder of thermoplastic 72 to be heated and thereby become flowable. When the ultrasonic energy is removed, the thermoplastic portion 72 is secured to the projection 62 of button 52. The thermoplastic portion 72 thereby enables the button 52 to be ultrasonically secured to fabric as is button 22 in FIG. 1.

FIG. 8 diagrammatically shows the securement of a button 52 having a thermoplastic portion 72 to a fabric which is not ultrasonically responsive for heavy duty wear. For example, in a heavy duty clothing such as work clothing where the material is usually of a cotton fabric and thus not ultrasonically responsive, in order to provide a heavy duty fastening between the button and the fabric of the garment, it is preferable to provide a reinforcement of thermoplastic on the lowermost surface of the material in order to cause securement between the button and the fabric which can take heavy duty use.

Thus, in order to secure the heavy duty button to heavy duty fabric, fixed ram 50 is used to secure the button 52 over fabric 74 which is passed over the dieplate 54. Fabric 74 is supported by the dieplate 54 when the desired portion of fabric 74 is located over opening 66, the ultrasonic ram 56 is elevated vertically thereby punching out a cylindrical portion of the thermoplastic sheet 58 which is passed through opening 66 and pressed against the lowermost surface of the material 74 by end 68 of the ram.

As best seen in FIG. 9, after the ram 56 abuts the lowermost surface of the fabric 74, ultrasonic energy is applied to the ram which vibrates vertically thereby transferring the ultrasonic energy to the thermoplastic portion 72 of button 52 and the thermoplastic portion cut out of the sheet 58 which is applied to the bottommost surface of the material 74. The ultrasonic energy causes the thermoplastic material to flow thereby causing the thermoplastic material to flow thereby causing an intermolecular connection between the thermoplastic portion 72 of button 52 and the thermoplastic portion which is provided below the material 74 causing a heavy duty securement between the button 52 and the material 74.

It can therefore be seen that a button which is not comprised of a thermoplastic material may be secured by ultrasonic energy to either a material which is or is not ultrasonically responsive by securing to the button a thermoplastic portion with ultrasonic energy.

The same apparatus can then be used to enable the securement of the button to fabric. Where the fabric is ultrasonically responsive, the thermoplastic portion can be secured directly to the fabric. However, where material or fabric is used which is not ultrasonically responsive, it may be preferable to provide a thermoplastic portion below the material for interconnection molecularly between the thermoplastic portion of the button and the extra thermoplastic applied to the opposite side of the material. A firm securement is thereby provided between the button and the material.

It can therefore be seen that a new and improved apparatus for securing buttons to fabric has been provided. The button may either be made completely of thermoplastic or have only a thermoplastic portion added thereto for purposes of securement of the button to the fabric.

The fabric may either be ultrasonically responsive or not. The ultrasonic securement is also extremely quick thereby providing an efficient means of securement of a button to fabric for automated processes of manufacture of clothing.

Moreover, the size of the ultrasonic coupling elements is also small enough so that a plurality of buttons can be secured on a shirt front or jacket front simultaneously so that only a single button securing operation is needed in the entire automated process.

Without further elaboration, the foregoing will so fully illustrate my invention that others may, by applying current or future knowledge, readily adapt the same for use under various conditions of service.

We claim:

1. Apparatus for securing one-piece buttons having a thermoplastic projection to porous fabric having interstices, said apparatus comprising means for holding said one-piece button, a plate to support said fabric, said plate having an opening therein, an ultrasonic ram being aligned with said opening, ultrasonic power means actuating said ram, said holding means fixed for maintaining said button in alignment with said plate opening to maintain said thermoplastic button projection in contact with one surface of said fabric, means to urge said ultrasonic ram through said plate opening and against another surface of said fabric, said last-named means simultaneously urging said fabric against said thermoplastic button projection, said ultrasonic power means supplying ultrasonic power to said thermoplastic button projection whereby said thermoplastic button projection flows into the interstices of said fabric to secure said button to said fabric.

2. The apparatus of claim 1 wherein said ram includes a cylindrical end portion that acts through said plate opening.

3. The apparatus of claim 1 wherein said thermoplastic projection of said button includes a plurality of pointed edges to facilitate the securement of said button to said fabric.

4. The apparatus of claim 1 wherein said button includes a nonultrasonically responsive portion in addition to said thermoplastic projection. 

1. Apparatus for securing one-piece buttons having a thermoplastic projection to porous fabric having interstices, said apparatus comprising means for holding said one-piece button, a plate to support said fabric, said plate having an opening therein, an ultrasonic ram being aligned with said opening, ultrasonic power means actuating said ram, said holding means fixed for maintaining said button in alignment with said plate opening to maintain said thermoplastic button projection in contact with one surface of said fabric, means to urge said ultrasonic ram through said plate opening and against another surface of said fabric, said last-named means simultaneously urging said fabric against said thermoplastic button projection, said ultrasonic power means supplying ultrasonic power to said thermoplastic button projection whereby said thermoplastic button projection flows into the interstices of said fabric to secure said button to said fabric.
 2. The apparatus of claim 1 wherein said ram includes a cylindrical end portion that acts through said plate opening.
 3. The apparatus of claim 1 wherein said thermoplastic projection of said button includes a plurality of pointed edges to facilitate the securement of said button to said fabric.
 4. The apparatus of claim 1 wherein said button includes a nonultrasonically responsive portion in addition to said thermoplastic projection. 